Foldable Structure

ABSTRACT

A single blank of sheet material is configured to be formed into a foldable structure having a bottom panel which defines a container region. The carton includes an end wall assembly having triangular panels configuring the end wall assembly to define a triangular opening.

REFERENCE TO RELATED APPLICATION

This patent claims priority of U.S. Provisional Patent Application Ser.Nos. 61/130,606 filed on Jun. 2, 2008 and 61/214,132 filed on Apr. 20,2009, and incorporates the same herein by reference.

FIELD OF THE INVENTION

The present invention relates to a foldable structure that may be cutfrom a single blank of sheet material and folded and assembled withoutthe use of glue, and more particularly, to an assembled structure havingtriangular opening at an end portion.

BACKGROUND OF THE INVENTION

Foldable structures are well known in the packaging art. Cartons aretypically constructed from flat blanks that are pre-cut from sheets ofpaperboard and pre-scored to create fold lines. The carton blankincludes a number of panels to form the sides of the carton. A blank fora rectangular carton or carton, for example, will have four main panels,which form the four sides of the carton. A closure flap is generallyattached to each of the top and bottom end of the blank to allow thecarton to be opened and closed when constructed. Additionally, minorflaps, or dust flaps, may be present at each of the top and bottom endof the blank. The minor flaps aid in keeping dust and debris out of thecarton.

Many different shapes and sizes of foldable structures are known in theprior art. In many prior art foldable structures, their assembly from ablank sheet of material to a form from which they can be easily foldedto or assembled to a desired configuration (e.g., a carton) ofteninvolves a gluing step. In the gluing step, one or more seams or sidesof the prior art structures are glued together in order to enable theblank sheet of material to be folded from a flat storage configurationto a desired configuration (e.g., a carton). In many prior art methodsof manufacturing foldable structures, the gluing step is necessary inorder for the structure to be folded or assembled to and maintain itsdesired configuration (e.g., a carton).

A disadvantage associated with the gluing step involved in manufacturingprior art foldable structures is that it necessitates at least one extrastep in the manufacturing process of forming a blank of sheet materialinto a desired configuration (e.g., a carton). This additional stepoften accounts for a significant percentage of the total time requiredin manufacturing a blank of sheet material into a desired configuration(e.g., a carton).

The gluing step also often adds significantly to the manufacturingcosts. This is especially so when only a limited number of productsembodying the invention are being produced and the cost involved inapplying glue to the blank of sheet material and incorporating a gluingstep in the overall assembly of the product cannot be spread over alarge number of products.

Additionally, the gluing is further disadvantageous for non-commercialassembly of a products such as foldable cartons by, for example a homeuser, since such a non-commercial user may not have the glue or thespecific type/grade of glue needed to complete assembly of the structurein situations which assembly is required.

What is needed to reduce the time and cost involved in the manufactureof foldable structures such as cartons is a product that can beassembled from a single blank of sheet material into a three-dimensionalconfiguration such as a box, scoop or other configuration that does notrequire glue or glue-like substances, or a gluing step in itsmanufacture.

SUMMARY OF THE INVENTION

The foldable structure of the present invention includes a structureformed from a single blank of sheet material and is assembled withoutthe use of glue or other adhesive materials. The structure may beconfigured as a carton and may include a bottom wall defining opposingfirst and second side ends and opposing top and bottom ends. A firstsidewall may be foldably connected to the first side end of the bottomwall and a second sidewall may be foldably connected to the second sideend of the bottom wall.

A bottom end wall assembly may be foldably connected to the bottom endof the bottom wall. The bottom end wall assembly may include a firstbottom end panel bordered by a first fold line and opposing second andthird fold lines. A second bottom end panel may be foldably connected tothe first bottom end panel along the first fold line with the secondbottom end panel also being bordered by a fourth fold line opposite thefirst fold line. A third bottom end panel may be foldably connected tothe second bottom end panel along the fourth fold line.

A first triangular bottom panel may be foldably connected to the firstbottom end panel along the second fold line and a second triangularbottom panel may be foldably connected to the first bottom end panelalong the third fold line.

BRIEF DESCRIPTION OF THE DRAWINGS

The objects and features of the invention may be understood withreference to the following detailed description of an illustrativeembodiment of the invention taken together with the accompanying drawingin which:

FIG. 1 is a plain view of a single sheet of material of a firstillustrated embodiment of the foldable structure of the presentinvention;

FIGS. 2-4 are perspective views depicting the folding of the singlesheet of material of FIG. 1;

FIG. 5 is a perspective view of a folded structure in the form of acarton formed from the single sheet of material of FIG. 1 in accordancewith a first illustrated embodiment;

FIG. 6 is a plain view of a single sheet of material of a secondillustrated embodiment of the foldable structure of the presentinvention;

FIGS. 7 and 8 are perspective views depicting the folding of the singlesheet of material of FIG. 6; and

FIG. 9 is a perspective view of a folded scoop formed from the singlesheet of material of FIG. 6 in accordance with a second illustratedembodiment.

DETAILED DESCRIPTION

Turning now descriptively to the drawings, in which similar referencecharacters denote similar elements throughout the several views, FIG. 5shows a first illustrated embodiment of the formed carton 150 of anembodiment of the present invention. The blank 10 of this firstillustrated embodiment of the carton 150 is shown in FIG. 1.

With reference to FIG. 1, the blank 10 of the first illustratedembodiment of the foldable structure of the present invention is cutfrom a single sheet of material such as paper board or cardboard. Theblank includes a substantially square bottom panel 12 at its center thatis bordered by four fold lines 14, 16, 18, 20.

First right and left side panels 22, 24 are formed unitarily with thebottom panel 12 and are separated from the bottom panel 12 by fold lines14, 18. Both the first right and left side panels 22, 24 are eachbordered by three additional fold lines 26, 28, 30, 32, 34, 36. It isnoted first right and left side panels 22, 24 are preferably identicallydimensioned relative to one another and are each preferably configuredas an isosceles trapezoid.

Second right and left side panels 38, 40 are formed unitarily with thefirst right and left side panels 22, 24, respectively, on opposite sidesof the first right and left side panels 22, 24 from the bottom panel 12.Second right and left side panels 38, 40 are respectively separated fromthe first right and left side panels 22, 24 by fold lines 28, 34.

It is to be appreciated that second right and left side panels 38, 40are preferably identically dimensioned relative to one another and areeach also preferably configured as an isosceles trapezoid. It is to befurther appreciated that the aforesaid isosceles trapezoid configurationof second right and left side panels 38, 40 are preferably respectivelyidentical to that of the aforesaid isosceles trapezoid configuration offirst right and left side panels 22, 24 wherein the first right sidepanel 22 is a mirror image of the second right side panel 38 (via foldline 28) and the first left side panel 24 is a mirror image of thesecond left side panel 40 (via fold line 34).

A first bottom end panel 42 is formed unitarily with bottom end panel 12and is separated therefrom by fold line 16 and is additionally borderedby fold lines 44, 46, 48. Second bottom end panel 50 is formed unitarilywith first bottom end panel 42 and is separated therefrom by fold line46 and is additionally bordered by fold line 52. And a third bottom endpanel 54 is formed unitarily with second bottom end panel 50 and isseparated therefrom by fold line 52.

It is to be appreciated that each first, second and third bottom endpanels 42, 50, 54 are preferably configured in a rectangularconfiguration having equal dimensions relative to one another.

On a opposing side of bottom panel 12 relative to first bottom end panel42, first top end panel 56 is formed unitarily with bottom end panel 12and is separated therefrom by fold line 20 and is additionally borderedby fold lines 58, 60, 62. Second top end panel 64 is formed unitarilywith first top end panel 56 and is separated therefrom by fold line 60and is additionally bordered by fold line 66. And a third top end panel68 is formed unitarily with second top end panel 64 and is separatedtherefrom by fold line 66.

It is to be appreciated that each first, second and third top end panels56, 64, 68 are preferably configured in a rectangular configurationhaving equal dimensions relative to one another. It is further to beappreciated that each first, second and third top end panels 56, 64, 68have respectively equal dimensions to first, second and third bottom endpanels 42, 50, 54.

A right bottom triangular panel 70 is unitarily formed with first rightside panel 22 and first bottom end panel 42. Right bottom triangularpanel 70 is separated from first right side panel 22 by fold line 26 andfrom first bottom end panel 42 by fold line 48 and is additionalbordered by fold line 72. Right bottom flap panel 74 is unitarily formedwith right bottom triangular panel 70 and is separated therefrom by foldline 72.

A right top triangular panel 76 is unitarily formed with first rightside panel 22 and first top end panel 56. Right top triangular panel 76is separated from first right side panel 22 by fold line 30 and fromfirst top end panel 56 by fold line 62 and is additional bordered byfold line 78. Right top flap panel 80 is unitarily formed with right toptriangular panel 76 and is separated therefrom by fold line 78.

A left top triangular panel 82 is unitarily formed with first left sidepanel 24 and first top end panel 56. Left top triangular panel 82 isseparated from first left side panel 24 by fold line 36 and from firsttop end panel 56 by fold line 58 and is additional bordered by fold line84. Left top flap panel 86 is unitarily formed with left top triangularpanel 82 and is separated therefrom by fold line 84.

A left bottom triangular panel 88 is unitarily formed with first leftside panel 24 and first bottom end panel 42. Left bottom triangularpanel 88 is separated from first left side panel 24 by fold line 32 andfrom first bottom end panel 42 by fold line 44 and is additionalbordered by fold line 90. Left bottom flap panel 92 is unitarily formedwith left bottom triangular panel 88 and is separated therefrom by foldline 90.

It is to be appreciated that each aforesaid triangular panel 70, 76, 82,88 are each identically dimensioned and configured as an equilateraltriangle. Likewise, each aforesaid flap panel 74, 80, 86, 92 are eachidentically dimensioned and configured as a rectangle.

The above described single blank of sheet material 10 is preferablyfolded and assembled into the first illustrated embodiment of the carton150 of the present invention without the use of glue or adhesives orother means of adhering one carton component to another.

In folding and assembling the above described blank 10 into the firstillustrated carton embodiment 150 of the present invention (FIG. 5), andwith reference now to FIGS. 2 and 3 (with continuing reference to FIG.1), the first bottom end panel 42 and right and left bottom triangularpanels 70, 88 are folded along fold lines 16, 26, 32 in an upwarddirection relative to bottom panel 12. The first left side panel 24 andleft top triangular panel 82 are then folded along fold lines 18 and 58,and similarly the first right side panel 22 and right top triangularpanel 76 are folded along fold lines 14 and 62, in an upward directionrelative to bottom panel 12.

It is to be appreciated that the triangular geometry of right and leftbottom triangular panels 70 and 88 cause the first bottom end panel 42to reside at an acute inclined angle relative to bottom panel 12.

The right and left bottom flap panels 74 and 92 are then folded alongrespective fold lines 72 and 90 in a downward direction until therespective end portions of each right and left bottom flap panel 74 and92 abut, or are in close proximity, to one another such that due to thetriangular fold lines 72, 90 of the right and left bottom triangularpanels 70, 88, the right and left bottom flap panels 74, 92 reside in aplane parallel to that of the bottom panel 12. As is partially shown inFIG. 3, first right and left side panels 22, 24 now form the respectiveopposing side walls of the formed carton 150.

With reference now to FIGS. 3 and 4 (with continuing reference to FIG.1), the second bottom panel 50 is folded along fold line 46 in adownward direction relative to bottom panel 12 such that the bottomsurface 51 of second bottom panel 50 is coplanar with the respective topsurfaces of right and left bottom flap panels 74, 92. Next, the thirdbottom panel 54 is folded about fold line 52 whereby the third bottompanel 54 is friction fitted into the triangular open end portion 100formed by first bottom end panel 42, right and left bottom triangularpanels 70, 88 and right and left bottom flap panels 74, 92 such that thebottom surface 55 of the third bottom panel 54 is coplanar with therespective bottom surfaces of right and left bottom flap panels 74, 92.

Similarly, first top panel 56 is folded along fold line 20 in an upwarddirection relative to bottom panel 12 whereby right and left flap panels80, 86 are then folded along respective fold lines 78 and 84 in adownward direction until the respective end portions of each right andleft top flap panel 80, 86 abut, or are in close proximity, to oneanother such that due to the triangular fold lines 78 and 84 of theright and left top triangular panels 76, 82 the right and left top flappanels 80, 86 reside in a plane parallel to that of the bottom panel 12.

Like the second bottom panel 50, the second top panel 64 is folded alongfold line 60 in a downward direction relative to bottom panel 12 suchthat the bottom surface of second top panel 64 is coplanar with therespective top surfaces of right and left top flap panels 80, 86. Andlike the third bottom panel 54, the third top panel 68 is folded aboutfold line 66 whereby the third top panel 68 is friction fitted into thetriangular open end portion formed by first top end panel 56, right andleft top triangular panels 76, 82 and right and left top flap panels 80,86 such that the bottom surface of the third top bottom panel 68 iscoplanar with the respective bottom surfaces of right and left top flappanels 80, 86.

The second right and left side panels 38, 40 may then be folded downwardalong respective fold lines 28, 34 relative to the bottom panel 12 toprovide additional structural integrity to respective first right andleft side panels 22, 24 forming the respective opposing sidewalls forcarton 150. Alternatively, the second right and left side panels 38, 40may be folded in a first upward and then downward movement alongrespective fold lines 28, 34 relative to the bottom panel 12 to provideat least a partial enclosure for the carton cavity 130 formed by carton150. Alternatively, it is to be appreciated the second right and leftside panels 38, 40 may be omitted from blank 10 or may be bound byperforated scored fold lines 28, 34 so as to be removed at the user'sdiscretion.

It is to be appreciated that the cross-sectional area of each opposingtriangular open end portion 100 of carton 150 forms a prism likeconfiguration having an equilateral triangle cross section.

The above description with reference to FIGS. 1-5 completes the assemblyof the blank 10 of FIG. 1 into its carton configuration 150 shown inFIG. 5.

The blank 200 of the foldable structure of a second illustratedembodiment of the second invention is similar to that of the firstillustrated embodiment with regards to having a open triangular endportion forming a prism like configuration having an equilateraltriangular cross section. The blank 200 of the second illustratedembodiment of the present invention is also cut from a single sheet ofcarton material such as paper board or card board. The blank is shown inFIG. 6 and includes a generally rectangular bottom panel 210 bounded bythree fold lines 212, 214, 216. Right and left side panels 218, 220 areformed unitarily with the bottom panel 210. The right and left sidepanels 218, 220 are provided on opposite sides of the bottom panel 210and are separated from the bottom panel by fold lines 212, 216respectively. The right and left side panels 218, 220 are preferably ofidentical dimensions with each configured as a triangle having a curvedwall 222, 224. Each right and left side panel 218, 220 is additionallybounded by another fold line 226, 228.

A right triangular panel 230 is unitarily formed with right side panel218, and on an opposite side of the bottom panel 210, a left triangularpanel 230 is unitarily formed with left side panel 220. Each right andleft triangular panel 230, 232 is each additionally bound by two foldlines 234, 236, 238, 240.

A right flap panel 242 is unitarily formed with right triangular panel230 and is separated therefrom by fold line 234. Likewise left flappanel 244 is unitarily formed with left triangular panel 232 and isseparated therefrom by fold line 238.

It is to be appreciated that each right and left triangular panel 230,232 is identically dimensioned and configured as an equilateraltriangle. Likewise, each aforesaid right and left flap panel 242, 244 isidentically dimensioned and configured as a rectangle.

A first end panel 246 is positioned intermediate the right and lefttriangle panels 230, 232 and is unitarily formed with the bottom panel210 and each right and left triangular panel 230, 232 being separatedtherefrom by respective fold lines 214, 236, 240. The first end panel246 having a generally rectangular configuration.

A second end panel 250 is unitarily formed with the first end panel 246and is separated therefrom by fold line 248. And a third end panel 254is unitarily formed with the second end panel 250 and is separatedtherefrom by fold line 252. Preferably the second and third end panels250, 252 are identically dimensioned relative to one another and areeach configured as an isosceles trapezoid, wherein the second end panel250 is a mirror image of the third end panel 254, via fold line 252.

A right triangular tab panel 256 is unitarily formed with a side portionof third end panel 254 and is separated therefrom by fold line 258. Andan opposite side portion of third end panel 254 is unitarily formed witha left triangular tab panel 260 and is separated therefrom by fold line262. Each right and left triangular tab panel 256, 262 is preferablyidentically dimensioned relative to one another.

The above described blank 200 of the second illustrated embodiment ofthe foldable structure of the present invention shown in FIG. 6 isquickly and easily folded into and assembled into its foldable structurescoop configuration 300 preferably without the use of glues or adhesivesor any other equivalent means of adhering one structural component toanother.

The illustrated embodiment of the scoop 300 of the present invention isassembled from the single blank 200 of sheet material shown in FIG. 6 insubstantially the same manner as the aforesaid first illustratedembodiment of the foldable structure of the present invention.

In folding and assembling the above described blank 200 into the scoop300 embodiment of the present invention (FIG. 8), and with reference nowto FIGS. 7 and 8 (with continuing reference to FIG. 6), the first endpanel 246 and right and left triangular panels 230, 232 are folded alongfold lines 214, 226, 228 in an upward direction relative to bottom panel210. The left side panel 220 and left triangular panel 232 are thenfolded along fold lines 216, 240, and similarly the right side panel 218and right triangular panel 230 are folded along fold lines 212, 236 inan upward direction relative to bottom panel 210.

It is to be appreciated that the triangular geometry of right and lefttriangular panels 230, 232 cause the first end panel 246 to reside at anacute inclined angle relative to bottom panel 210.

With primary reference now to FIG. 8, the right and left flap panels242, 244 are then folded along respective fold lines 234, 238 in adownward direction until the respective end portions of each right andleft flap panel 242, 244 abut, or are in close proximity, to one anothersuch that due to the triangular fold lines 234, 238 of the right andleft triangular panels 230, 232, the right and left flap panels 242, 244reside in a plane parallel to that of the bottom panel 210. As ispartially shown in FIG. 8, right and left side panels 218, 220 now formthe opposing side walls of the formed scoop 300.

The second end panel 250 is then folded along fold line 248 in adownward direction relative to bottom panel 210 such that the bottomsurface 251 of second end panel 250 is coplanar with the respective topsurfaces of right and left flap panels 242, 244. Next, the third endpanel 254 is folded about fold line 252 whereby the third end panel 254is friction fitted into the triangular open end portion 270 formed byfirst end panel 246, right and left triangular panels 230, 232 and rightand left bottom flap panels 242, 244 such that the bottom surface 255 ofthe third end panel 254 is coplanar with the respective bottom surfacesof right and left flap panels 242, 244. Similarly, the right triangulartab panel 256 abuts adjacent the right triangular panel 230 (as shown inFIG. 8) and the left triangular tab panel 260 abuts adjacent the lefttriangular panel 232.

It is to be appreciated that right and left triangular tab panels 256,262 may be omitted from blank 200 or may be bound by perforated scoredfold lines 258, 262 so as to be removed at the user's discretion.

The above description with reference to FIGS. 6-9 completes the assemblyof the blank 200 of FIG. 6 into its scoop 300 configuration shown inFIG. 9. Specifically, scoop 300 is formed as a scoop-like structurehaving a scoop-like open end 310 portion for scooping and retainingobjects in a carton region 330 formed by the aforesaid panels of blank200.

And like carton 150 of the first illustrated embodiment (FIG. 5), it isto be appreciated that the cross-sectional area of the formed triangularopen end portion 270 of scoop 300 forms a prism like configurationhaving an equilateral triangle cross section.

While the illustrated embodiments of the present invention has beendescribed by reference to specific embodiments, it should be understoodthat modifications and variations of the invention may be constructedwithout departing from the scope of the invention defined herein and bythe following claims.

1. A carton formed from a single blank of sheet material, the cartoncomprising: a bottom wall defining opposing first and second side endsand opposing top and bottom ends; a first sidewall foldably connected tosaid first side end of said bottom wall; a second sidewall foldablyconnected to said second side end of said bottom wall; a bottom end wallassembly foldably connected to said bottom end of said bottom wall, saidbottom end wall assembly including: a first bottom end panel bordered bya first fold line and opposing second and third fold lines; a secondbottom end panel foldably connected to said first bottom end panel alongthe first fold line, said second bottom end panel also bordered by afourth fold line opposite said first fold line; a third bottom end panelfoldably connected to said second bottom end panel along the fourth foldline; a first triangular bottom panel foldably connected to said firstbottom end panel along said second fold line; and a second triangularbottom panel foldably connected to said first bottom end panel alongsaid third fold line.
 2. The foldable structure of claim 1, wherein thefirst triangular bottom panel is also bordered by fifth and sixth foldlines and the second triangular bottom panel is bordered by seventh andeighth fold lines with said first sidewall foldably connected to saidfirst bottom triangular panel along said fifth fold line and said secondsidewall foldably connected to said second triangular bottom panel alongsaid seventh fold line, said bottom end wall assembly further including:a first bottom flap panel foldably connected to said first triangularbottom panel along said sixth fold line; and a second bottom flap panelfoldably connected to said second triangular bottom panel along saideight fold line.
 3. The foldable structure of claim 2 further includinga top end wall assembly foldably connected to said top end of saidbottom wall.
 4. The foldable structure of claim 3 wherein said top endwall assembly includes: a first top end panel bordered by a ninth foldline and opposing tenth and eleventh fold lines; a second top end panelfoldably connected to the first top end panel along the ninth fold line,said second top end panel also bordered by a twelfth fold line oppositesaid ninth fold line; a third top end panel foldably connected to saidsecond top end panel along said twelfth fold line; a first triangulartop panel foldably connected to said first top end panel along saidtenth fold line; and a second triangular top panel foldably connected tosaid first top end panel along said eleventh fold line.
 5. The foldablestructure of claim 4, wherein the first triangular top panel is alsobordered by thirteenth and fourteenth fold lines and the secondtriangular top panel is bordered by fifteenth and sixteenth fold lineswith said first sidewall foldably connected to said first top triangularpanel along said thirteenth fold line and said second sidewall isfoldably connected to said second triangular top panel along saidfifteenth fold line, said top end wall assembly further including: afirst top flap panel foldably connected to said first triangular toppanel along said fourteenth fold line; and a second top flap panelfoldably connected to said second triangular top panel along saidsixteenth fold line.
 6. The foldable structure of claim 1 wherein saidfirst and second sidewall are configured as rectangles.
 7. The foldablestructure of claim 1 wherein said first, second and third bottom panelsof said bottom end wall assembly are configured as rectangles.
 8. Thefoldable structure of claim 1 wherein said first and second triangularbottom panels of said bottom wall assembly are configured as equilateraltriangles.
 9. The foldable structure of claim 5 wherein said first,second and third bottom panels of said top end wall assembly areconfigured as rectangles.
 10. The foldable structure of claim 5 whereinsaid first and second triangular top panels of said top end wallassembly are configured as equilateral triangles.